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INVERTER-Y TRAINING 2009. TOPICS. Introduction to Y-Inverter Control Algorithm Troubleshooting. INTRODUCTION. INTRODUCTION. What is inverter ? What are the advantages ? Differences between Conventional & Inverter A/C Basics of Inverter Technology. INTRODUCTION. What is Inverter?.

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Presentation Transcript
slide1

INVERTER-Y

TRAINING 2009

slide2

TOPICS

Introduction to Y-Inverter

Control Algorithm

Troubleshooting

slide4

INTRODUCTION

  • What is inverter ?
  • What are the advantages ?
  • Differences between Conventional & Inverter A/C
  • Basics of Inverter Technology
slide5

INTRODUCTION

What is Inverter?

  • Electrical supply has fix frequency
  • Inverter type air conditioner have frequency changer which can change the electrical frequency to control the speed of the compressor
  • This in turn, can control the capacity accordingly
slide6

INTRODUCTION

Advantages

  • Enhanced room temperature comfort

- More precise room temperature control

- Temperature fluctuation is kept within ± 0.5C from set temperature

Conventional

Inverter

slide7

INTRODUCTION

Conventional compressor

Compressor capacity

Full capacity

Time

Advantages

  • Less on / off cycle

Room temperature control:

switching compressor ON & OFF

Compressor capacity

Inverter

Room temperature control:

Control compressor rotational speed smoothly

Smooth ramp up from zero to high rotational speed

Slow down as temperature drops

Maintain room temperature at low speed

Time

slide8

INTRODUCTION

Advantages

  • Starting frequency

Compressor frequency

(rps)

1.0 hp – 68 rps

1.5 hp – 74 rps

Max.

55

35

Target frequency

20

0

Time (min)

2

1

6

slide9

INTRODUCTION

Advantages

  • Fast cooling

Conventional non-inverter A/C

Inverter A/C

Room temperature

Set temperature

Time

Quick cooling

slide10

INTRODUCTION

Advantages

  • Low starting current

Running current

Conventional A/C:

  • High starting current
  • Frequent on/off cycle

Inverter A/C:

  • Low starting current
  • Smooth operation

Hours of operation

slide11

INTRODUCTION

Advantages

  • Higher reliability
  • Less compressor start – stop cycle
  • Low starting current
  • Longer compressor motor lifespan
slide12

INTRODUCTION

Advantages

  • Low energy consumption with superior efficiency
  • Frequency of supply current is varied according to load requirements – excellent efficiency
  • Range is between

0 – 68 rps (204 Hz) for 1.0 hp

0 – 74 rps (222 Hz) for 1.5 hp

  • Resulting in significantly LESS compressor start/stop – low energy consumption

Lowest operating frequency = 60 Hz

slide13

INTRODUCTION

Advantages

  • Protection

Additional software protection against

  • Over current
  • Over heating
slide14

INTRODUCTION

Differences Overview

slide15

INTRODUCTION

Energy Savings

Creation of Comfort

Basics of Inverter Technology

Inverter-driven Compressor

IPM (Inverter Power Module)

Electronic Expansion Valve (EXV)

slide16

INTRODUCTION

Basics of Inverter Technology

Power supply

Rectifier circuit

Compressor Motor

IPM

Adjust capacity according to actual load by

  • Controlling the EXV opening
  • Controlling the refrigerant flow
slide17

INTRODUCTION

Compressor

Energy

Source

Rectifying

Circuit

Inverter

Circuit

Control & Protection

Circuitry

Feedback

Basics of Inverter Technology

Inverter system block diagram

slide18

INTRODUCTION

Basics of Inverter Technology

Inverter drive power circuit

IN

U

M

V

OUT

W

Rectifier

Inverter

slide19

INTRODUCTION

Basics of Inverter Technology

What are Rectifier / Inverter?

Rectifier:

Rectifying with smoothing

Changing AC  DC

Inverter:

Inverse transformation with P.W.M.

Changing DC  AC

slide20

INTRODUCTION

IN

U

M

V

OUT

W

Basics of Inverter Technology

Inverter drive power circuit - components

IPM(Inverter Module)

Reactor

Diode

Electrolytic capacitor

slide21

INTRODUCTION

t1

50 Hz

Basics of Inverter Technology

The system

Inverter Output

Frequency

222 Hz 60 Hz

Power supply

Input frequency

50Hz

Inverter

AC/DC

Rectifier

DC/AC

Inverter

u

t

t

222 Hz

60 Hz

compressor motor input

IPM

slide22

INTRODUCTION

Basics of Inverter Technology

Indoor PCB

slide23

INTRODUCTION

Basics of Inverter Technology

Outdoor PCB

frequency principle
The compressor is frequency-controlled during normal operation. The target frequency is set based on following parameters:

i) Outdoor ambient temperature

ii) Set temperature

iii) Room temperature

When the frequency increases, the rotation speed of compressor increases resulting in an increased refrigerant circulation, this lead to higher amount of heat transfer and vice versa when frequency decreases.

Frequency Principle

CONTROL ALGORITHM

operating modes
The system has 2 operating modes. The mode selection is done in Inverter (indoor) controls.

The operating modes are:

Cool

Fan

Operating Modes

CONTROL ALGORITHM

slide27

CONTROL ALGORITHM

Function – Cool Mode

  • When Tr >= Ts – 1.5°C

- Comp, ID Fan and OD Fan ON

  • When Tr <= Ts - 2°C

- Comp and OD Fan OFF

- ID Fan remain ON

Tr = Room Temperature

Ts = Set Temperature

function cool mode
At beginning of cooling operation, compressor frequency will be increased smoothly to the target frequency so that the room temperature is reduced.

When set temperature is achieved, operation frequency will be reduced to stabilize the room temperature.

Function – Cool Mode

CONTROL ALGORITHM

slide29

CONTROL ALGORITHM

When will Compressor Stop?

  • When cooling load is too small, even with lowest operation frequency and the room temperature still fall below compressor cut off point, compressor will stop.

Compressor Capacity

Lowest Freq

Time

Tr <= Ts - 2°C

Comp will stop

function fan mode
Function - Fan Mode

Only High, Medium and Low fan speeds are allowed.

When changing cool mode to fan mode, the compressor will stop and OD fan stops after 30s.

Compressor will only ON if the minimum stop time is > 3 minutes and the user change back to cool mode.

Fan speed will maintain same as during fan mode.

CONTROL ALGORITHM

slide31
Master by outdoor unit.

Indoor controller board will transmit signal to outdoor

controller board every 0.5s. Outdoor unit will response to

indoor once the valid data is received.

PROTECTION

Indoor

Acknowledge

Send Signal

Outdoor

Protection Control - Data Communication Error

Between Indoor and Outdoor

slide32
If the data communication line between indoor and outdoor

occurs error for 15scontinuously, compressor will

stop, OD fan stop after 30s. ID LED blinks error.

If the communication resumes after 15s, error code is clear

and compressor restarts after 3 minutes.

If the communication is not resume after 15s, unit unable to

restart and the error keep blinking.

PROTECTION

Protection Control - Data Communication Error

Between Indoor and Outdoor

slide33
Indoor Coil Frost Prevention

Only available in cooling mode.

When the indoor coil temperature < 2°C, the compressor starts to drop the frequency.

This protection is activated when:

- Indoor coil temperature < 0°C for more than 180s. Compressor will stop, OD fan stop after 30s and indoor fan can only run at super low fan speed.

The unit can only be restarted after 3 minutes.

When the indoor coil temperature >13°C, the compressor frequency will be reset based on the OD ambient, room and set temperature.

PROTECTION

input current control1
Input Current Control

When the input current for running compressor exceeds I2, running frequency will be reduced by 1 step. If current still exceeds I2, frequency will be reduced by another 1 step until total current falls between I2 and I3.

This protection is activated when the input current exceeds I1 for 2 seconds. Compressor will stop and it is considered total current overload.

The unit can only be restarted after 3 minutes.

If input current <I3, the compressor frequency is reset based on the OD ambient, set and room temperature.

PROTECTION

slide37
If compressor discharge temperature >102°C, running frequency will be reduced by 1 step. If compressor discharge temperature still >102°C, frequency will be reduced by another 1 step until temperature falls between 99°C and 90°C.

This protection is activated when the compressor discharge temperature > 110°C. The compressor will stop and considered trip.

The unit can only be restarted after 3 minutes.

If the compressor discharge temperature < 90°C, the compressor frequency will be reset based on the OD ambient, set and room temperature.

PROTECTION

Compressor Discharge Temperature Control

slide38

PROTECTION

High Pressure Protection

slide39
The compressor frequency is adjusted depend on the coil temperature.

This protection is activated when the outdoor coil temperature > 64°C, the compressor stop and OD fan stop after 30s.

The unit can only be restarted after 3 minutes.

PROTECTION

High Pressure Protection

slide40
Protection on the IPM

IPM error is declared when;

i) Compressor’s motor peak current > 21A OR

ii) IPM temperature >100°C OR

iii) IGBT peak current > 16A.

PROTECTION

IPM error

slide42

TROUBLESHOOTING

Fault display by indoor unit

When any error occurs, indoor LED display will keep blinking

LED blinks here

slide43

TROUBLESHOOTING

Fault diagnosis by remote controller

TIMER CANCEL button

Hold down ON TIMER CLR or

OFF TIMER CLR for 5 seconds

slide44

TROUBLESHOOTING

Fault diagnosis by remote controller

Press TIMER CANCER repeatedly until ID buzzer produces long beep

The handset temperature display section will indicate the error code

Error code

ID unit buzzer will produce long beep if the handset error code = unit error

A short and two consecutive beeps is not the unit error

slide45

TROUBLESHOOTING

Fault diagnosis using outdoor 7-segment display

slide46

TROUBLESHOOTING

Fault diagnosis using outdoor 7-segment display

7-segment display

When there is no error, compressor running frequency is displayed, unit: rps

Flashes error code when error occurs

slide47

TROUBLESHOOTING

Fault diagnosis – stored last state error

Remove battery from remote controller

Replace battery again into remote controller

Press Mode & ON/OFF buttons together

Press Mode button to 5:00

Press ON/OFF once

Repeat the fault diagnosis by remote controller steps

Mode button

TIMER CANCEL button

ON/OFF button

slide48

TROUBLESHOOTING

Error Codes

slide49

TROUBLESHOOTING

Outdoor 7-segment display

Press on the tact switch

Display parameter by flashing of 7-segment

Parameter 125, display as 25, follow by 01

slide50

TROUBLESHOOTING

Equipments

  • Digital clampmeter
  • Digital multi-meter
  • Pressure gauge

AC CURRENT

RESISTANT

AC VOLTAGE

slide51

TROUBLESHOOTING

Error C4 – ID coil thermistor short /open

  • Remove the ID coil thermistor from PCB
  • Set digital multi-meter to ohm reading
  • Measure both terminals on the sensor using multi-meter test leads
  • The reading must comply with a particular temperature, refer Table 3
  • If the reading differs by ±2°C. It is acceptable
slide52

TROUBLESHOOTING

Resistance - temperature

At 25C

Resistance value: 10 k

slide53

TROUBLESHOOTING

Error C9 – Room thermistor short /open

Sensor RTH201

  • Possibility – low
  • Unit design with air opening at the front panel to allow sufficient space for air flow & measurement
  • 10 C < operating temp. < 40 C

Air intake gap for room temperature sensing

slide54

TROUBLESHOOTING

Error H9 – OD air thermistor short /open

Error J3 – Compressor discharge pipe thermistor short /open / misplaced

Error J6 – OD coil thermistor short /open

Share a same connector

Connection to PCB

slide55

TROUBLESHOOTING

Error H9 – OD air thermistor short /open

Thermistor

  • Remove the OD air thermistor from PCB
  • Set digital multi-meter to ohm reading
  • Measure both terminals on the sensor using multi-meter test leads.
  • The reading must comply with a particular temperature, refer Table 3
  • If the reading differs by ±2°C. It is acceptable
slide56

TROUBLESHOOTING

Error J3 – Compressor discharge pipe thermistor short /open / misplaced

Thermistor

  • Remove the compressor discharge pipe thermistor from PCB
  • Set digital multi-meter to ohm reading
  • Measure both terminals on the sensor using multi-meter test leads.
  • The reading must comply with a particular temperature, refer Table 3
  • If the reading differs by ±2°C. It is acceptable
slide57

TROUBLESHOOTING

Error J6 – OD coil thermistor short /open

Thermistor

  • Remove the OD coil thermistor from PCB
  • Set digital multi-meter to ohm reading
  • Measure both terminals on the sensor using multi-meter test leads.
  • The reading must comply with a particular temperature, refer Table 3
  • If the reading differs by ±2°C. It is acceptable
slide58

TROUBLESHOOTING

Error P4 – Heat sink thermistor short /open

  • Remove the heat sink thermistor from PCB
  • Set digital multi-meter to ohm reading
  • Measure both terminals on the sensor using multi-meter test leads.
  • The reading must comply with a particular temperature, refer Table 3
  • If the reading differs by ±2°C. It is acceptable
slide59

TROUBLESHOOTING

Error E8 – AC input over current

  • Set clamp meter to AC current
  • Clamp terminal 1 on the OD unit terminal block
  • If the reading < 10 Amp. It is acceptable
slide60

TROUBLESHOOTING

Error U2 – DC voltage out of range

  • Set multi-meter to DC voltage
  • Measure terminals 1 & 2 on the OD unit terminal block using multi-meter test leads
  • If the reading is within 220-240 V. It is acceptable

positive lead (+)

negative lead (-)

slide61

TROUBLESHOOTING

Error F6 – High pressure protection

  • Coil overload
  • Possible causes: coil dirty and air short circuit

Where a wall or other obstacle is in the path of outdoor unit’s intake or exhaust airflow

Follow this installation guidelines to avoid air short circuit

slide62

TROUBLESHOOTING

Error L5 – IPM / IGBT error

  • Possible causes: over current or over heat
  • At start up: could be due to software
  • After running some time: could be due to over current or over heat

Heat sink

IPM

slide63

TROUBLESHOOTING

Error UO – Insufficient gas

Check pressure reading at rated capacity

Press & hold

  • Connect pressure gauge to OD service valve
  • Press and hold on the ID ON/OFF button
  • Set to high fan mode and temperature at 16 °C using remote controller
  • Under cooling mode:

For 1.0 hp: at 45 rps, the pressure reading should be between 125 – 150 psi

For 1.5 hp: at 65 rps, the pressure reading should be between 125 – 150 psi

slide64

TROUBLESHOOTING

Error U4 – Communication error

  • Maximum communication wire length up to 30 meters
  • Make sure the recommended type of wire is used
  • External interference or noise
  • Check for loose connection
slide65

TROUBLESHOOTING

Error UA – Installation error

Y5WMY10/15J

Y5SLY10/15D